US8124192B2 - Layer application device for an electrostatic layer application of a building material in powder form and device and method for manufacturing a three-dimensional object - Google Patents

Layer application device for an electrostatic layer application of a building material in powder form and device and method for manufacturing a three-dimensional object Download PDF

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Publication number
US8124192B2
US8124192B2 US12/215,045 US21504508A US8124192B2 US 8124192 B2 US8124192 B2 US 8124192B2 US 21504508 A US21504508 A US 21504508A US 8124192 B2 US8124192 B2 US 8124192B2
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powder
layer
building
application
building material
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US20090017219A1 (en
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Norman Paasche
Thomas Brabant
Stefan Streit
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3D MICROPRINT GmbH
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3D Micromac AG
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Assigned to EOS GMBH ELECTRO OPTICAL SYSTEMS reassignment EOS GMBH ELECTRO OPTICAL SYSTEMS ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BRABANT, THOMAS, PAASCHE, NORMAN, STREIT, STEFAN
Publication of US20090017219A1 publication Critical patent/US20090017219A1/en
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Assigned to 3D MICROPRINT GMBH reassignment 3D MICROPRINT GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: 3D-MICROMAC AG
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/003—Apparatus, e.g. furnaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/30—Platforms or substrates
    • B22F12/37—Rotatable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50—Means for feeding of material, e.g. heads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/30—Platforms or substrates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the invention is related to a layer application device for an electrostatic layer application of a building material in powder form and in particular to a device and a method for a layer-wise manufacturing of a three-dimensional object, which device and method apply the layer application device.
  • a device and a method for the manufacturing of a three-dimensional object by selective laser sintering are for example known from U.S. Pat. No. 5,908,569.
  • a respective device is shown in FIG. 1 and will be briefly described in the following.
  • the laser sintering device shown in FIG. 1 has a container 1 that is open to the top, in which a support 4 for supporting the object 6 to be formed is provided. By means of a drive in the container the support 4 can be moved, up and down in a vertical direction. Above the container 1 a laser 14 is arranged as irradiation device that emits a directed light beam 15 . Via a deflection device 16 this light beam 15 is deflected towards the object 6 to be manufactured layer-wise.
  • FIG. 2 shows an application device from WO 2006/122645, which is a coating device 24 having two blades 21 a and 21 b , which are held together at their sides by two sidewalls in parallel to the drawing plane, which are not shown.
  • the two blades and the two sidewalls together form a supply chamber 22 that is open to the top and to the bottom and serves for receiving the powder material for a layer.
  • the coating device 24 By moving the coating device 24 into the direction of the arrow B the powder 27 from the supply chamber 22 is spread across the surface 5 , wherein the powder layer is smoothed down by the blades 21 a and 21 b.
  • German Patent Application Document DE 199 52 998 a device for a direct manufacturing of bodies is described, in which two building chambers and two powder supply chambers, respectively, lie opposite to one another similarly to quarters of a circle.
  • the cover plate which is formed to be a doctor, the powder is then shifted from a supply container to the adjacent building container.
  • the powder application is also effected by means of a rotatable doctor that is designed such that it has the shape of a ring, wherein the ring as a whole is rotated around an axis of rotation that lies outside of the ring.
  • U.S. Pat. No. 4,863,538 discloses a method and a device for manufacturing objects by means of selective sintering.
  • a pre-defined amount of the powder material is put on a support that can be lowered and is spread by means of a roller that can be moved across the support while at the same time being rotated in a direction opposite to the direction of movement across the support.
  • a blade, a roller or a doctor is used for the layer application.
  • the blade, the doctor or the roller in all cases applies mechanical force not only to the powder.
  • the powder layer has been applied onto a previously solidified layer of the part to be manufactured, then inevitably portions of the part that are already present are subjected to this force, which in general acts in a shearing way. From this a crack or a deformation may result, in particular in fragile structures or thin-wall structures. This has disadvantageous effects on the aspect ratio and the dimensional accuracy of the object to be formed.
  • the object of the invention is to provide a device for a contact-free layer application, in which the above described problems no longer occur.
  • a thereby optimized device for a layer-wise manufacturing of parts by means of sintering as well as a respective method shall be provided.
  • the object of the invention is achieved by a device for applying powder onto an application surface having a powder container ( 35 ) and a voltage source ( 32 ) for applying a voltage between the powder container ( 35 ) and the application surface, wherein the powder container ( 35 ) at least partially consists of a conductive material and the powder container ( 35 ) has an opening ( 35 a ) or is completely open at its side facing the application surface, when a voltage is applied.
  • the device of the present invention also can comprise one or more of the following features:
  • the present invention also provides a device for manufacturing a three-dimensional object by solidifying layers of a material in powder form at the positions corresponding to the respective cross section of the object having a powder application device as described herein, and a building platform ( 31 ) for supporting the object to be formed, on which building platform the powder is applied by means of the powder application device.
  • the device for manufacturing a three-dimensional object in accord with the invention further comprises one or more of the following features:
  • the object of the invention is also achieved by a method for a layer-wise manufacturing of a three-dimensional object having the steps: applying a layer of a building material in powder form onto the application surface of a building platform ( 31 ) or a previously solidified layer and selectively solidifying the applied layer at the positions corresponding to the cross-section of the object, characterized in that the powder is applied by generating an electric field between the powder container ( 35 ) and the building platform ( 31 ).
  • Methods for a layer-wise manufacturing of a three-dimensional object also can comprise one or more of the following features:
  • FIG. 1 shows a laser sintering device of the prior art
  • FIG. 2 shows a powder application device of the prior art
  • FIG. 3 shows a device according to a first embodiment of the invention during the powder application
  • FIG. 4 shows a device according to a first embodiment of the invention during the selective layer solidification
  • FIG. 5 shows a second embodiment of the invention
  • FIG. 6 shows a third embodiment of the invention
  • FIG. 7 shows several powder reservoirs according to a fourth embodiment of the invention.
  • FIGS. 3 and 4 show a first embodiment of the invention.
  • a layer application device according to the invention is shown that is used in a laser sintering device.
  • FIG. 3 shows the laser sintering device during the layer application
  • FIG. 4 shows the same device during the layer solidification.
  • a building container 34 in which a three-dimensional object is manufactured layer-wise on a building platform 31 is shown in detail.
  • the building platform 31 is mechanically connected to a lifting device 36 , wherein the lifting device is able to move the building platform in a vertical direction up and down.
  • a powder container 35 with powder that shall serve as a building material for the building-up of the object is arranged.
  • a high-voltage source 32 a high-voltage is applied between the building platform 31 and the powder container 35 , which high-voltage typically is in a range from 100 V to 40 kV, for example 10 kV.
  • the building platform 31 is mechanically connected to the lifting device 36 via an insulator 33 in order to guarantee an electric decoupling.
  • a powder layer can be applied onto the building platform in a contact-less way as follows:
  • the particles start to move in the electric field, because, depending on their own charge, they are attracted either to the positive electrode or the negative electrode (the building platform and the powder container, respectively).
  • the particles in the powder reservoir are neutral in total. However, they have to be regarded as charges that are more or less insulated. Therefore, the electrodes separate particles of different charge from one another by attracting particles having an opposite charge and repelling those having the same charge.
  • the fact that neighbouring separate powder particles of the same charge repel each other is of relevance here. This leads to a uniform packing density of the particles on the building platform surface and prevents the formation of conglomerates on the surface. Unevenly charged particles attract each other, however, are separated in the electric field, so that in the end the particles in the field are kept at a distance to each other and there are no imperfections in the layer due to unevenly charged particles.
  • a layer can be applied onto the building platform or the surface of a previously solidified layer (in the following generally an ‘application surface’ is mentioned) merely by providing the necessary electric field.
  • the layer application is controlled via the field strength that is generated between the electrodes and the duration of time, during which the electric field is applied.
  • the necessary field strength need not be adjusted via the applied voltage alone. It is also possible to adjust the field strength via the distance between the powder container and the building platform. This can be effected by means of the lifting device 36 .
  • the powder container can then be moved by moving it in the space and/or rotating it around a (for example vertical) axis that is lying outside of the powder container.
  • the electric field can also cause a compaction of the powder in the powder reservoir, which is undesired, there is provided a shaking mechanism or a vibration mechanism 43 at the powder container 35 , by which such a compaction can be successfully opposed.
  • the powder container can be elastically suspended with a motor being attached to the bottom side of the powder container, wherein the motor has an eccentric weight at the axis of rotation.
  • a shaking movement of the mounting of the powder container can be effected.
  • various shaking devices or vibrators, ultra-sound vibrators or stirring devices may be used. Due to the shaking movement and due to the effect of the electric field an equilibrium between adhering powder and powder that has been repelled again is reached between the electrodes (building platform/powder container), which is shown in the figures by a cloud.
  • FIG. 4 shows the device according to the first embodiment in a state in which an applied powder layer is being solidified.
  • a laser beam source 39 is shown, which directs a beam that has been deflected by a deflection device 38 through a beam entrance window 40 onto the powder layer on the building platform 31 .
  • the powder container is moved away from the building platform 31 by means of the drive 37 and the irradiation device ( 38 , 39 ) is moved under the building platform 31 .
  • the irradiation device is stationary and only the powder container is moved. During the exposure the high voltage is switched off. However, it is also conceivable to keep the voltage being applied, because the necessary field strength for a powder application is not attained due to the large distance between the powder container 35 and the building platform 31 .
  • the building platform 31 In order to prevent the powder particles from coming off the building platform 1 , which is facing downward according to embodiment 1, in the course of time, it is advantageous to have the building platform 1 facing downwards only during the powder application.
  • the building platform 31 therefore is no longer rigidly connected to the lifting device 36 , but can be rotated around a horizontal axis 42 by means of a rotating device 41 . Thereby it is possible to turn the building platform up via a rotation around the axis of rotation 42 after the completion of the application procedure, so that the applied layer faces the beam entrance window.
  • the building platform 31 is spatially separated from the mounting at the lifting device 36 by means of an insulator 33 , which at the same time electrically decouples the building platform from the lifting device.
  • an insulator 33 which at the same time electrically decouples the building platform from the lifting device.
  • the building platform 31 cannot be in the upper exposure position and the lower powder application position at the same time. Therefore, the building platform is shown with a dashed line in the exposure position in order to make clear that both positions of the building platform are occupied at different times.
  • the exposure need not necessarily be effected in the upper position in FIG. 5 .
  • the exposure device might as well be located laterally to the axis of rotation 42 , so that between the powder application position and the exposure position there is merely a rotation by an angle of 90°. Very generally it is possible to choose an arbitrary angle differing from 180°.
  • FIG. 6 shows a view of a device according to a third embodiment of the invention as seen from a position on the axis of rotation 42 .
  • Building platforms 31 a , 31 b , 31 c , 31 d that are arranged around the axis of rotation 42 having an angle of 90° to one another can be seen. Except this plurality of building platforms together with their respective mountings the device according to the third embodiment is identical to the one of the second embodiment.
  • the third embodiment it is for example possible that during the powder application onto the building platform 31 a simultaneously the powder layer that has been previously applied onto the building platform 31 c is exposed from above. This leads to a reduction of the building time.
  • four building platforms are shown as an example, it is as well possible to use a different number of building platforms, in particular two building platforms opposite to one another.
  • the exposure need not always be effected on the building platform that is facing upwards (building platform 31 c in FIG. 6 ), but might as well be effected at the building platform facing to the left or to the right (building platforms 31 d and 31 b , respectively).
  • FIG. 7 shows a device according to a fourth embodiment of the invention.
  • FIG. 7 Compared to the devices of the previous embodiments there are several powder containers 35 (in FIG. 7 as an example two) present in the fourth embodiment.
  • the individual powder containers may contain different materials, it is thus possible to successively apply layers of different powder materials. For instance, at first a powder layer can be applied by the right container in FIG. 7 and can be sintered. In the next layer application procedure the container shown in FIG. 7 at the left can then be moved under the building platform 31 , which is facing downwards.
  • an arbitrary succession of material layers is possible.
  • There is as well the possibility to mix powder from several different containers during the application of one powder layer by moving plural powder containers under the building platform 21 for an application of the mentioned one layer.
  • the velocity of a powder particle that hits the building platform when a high voltage is applied depends on the field strength and thus on the acceleration voltage.
  • a high voltage in the form of a pulsed direct voltage that causes an intermittent movement of the powder particles towards the building platform 21 , whereby a “knocking in” is implemented.
  • functional surfaces meaning portions and cut-outs, respectively, of larger surfaces, which potentially are subjected to a higher wear, for example because they serve as guideway, may be selectively made more wear-resistant by the method according to the invention.
  • at least one layer of a ceramics material or of another material can be applied in order to finish the surfaces of such guidance faces and thereby specifically make them more wear-resistant.
  • the powder container 35 is completely open to the building platform 31
  • the powder container 35 can be designed such that it is a metallic conducting swap cartridge that is inserted into a vibrator insert of the vibration mechanism 43 .
  • the cartridges are provided with an opening mechanism that is designed such that the cartridge in each case is opened before the powder application and is closed after the extraction of the powder.
  • structures and bodies may be integrated in existing bodies, which would be impossible in doctor-based sintering machines.
  • the application of powder may also take place in recesses, whereby powder may be applied later in existing geometric bodies such as in cavities and then solidified.
  • gears having a wear-resistant geared ring can be produced with a high precision in a cost-effective way.
  • Another application is the insertion of precise walls or geometries in conventionally manufactured packages or similar.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Plasma & Fusion (AREA)
  • Powder Metallurgy (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Electrostatic Spraying Apparatus (AREA)
  • Heating, Cooling, Or Curing Plastics Or The Like In General (AREA)
US12/215,045 2007-06-25 2008-06-24 Layer application device for an electrostatic layer application of a building material in powder form and device and method for manufacturing a three-dimensional object Active 2029-05-01 US8124192B2 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102007029142.8 2007-06-25
DE102007029142 2007-06-25
DE102007029142A DE102007029142A1 (de) 2007-06-25 2007-06-25 Schichtauftragsvorrichtung zum elektrostatischen Schichtauftrag eines pulverförmigen Werkstoffes sowie Vorrichtung und Verfahren zum Herstellen eines dreidimensionalen Objektes

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US20090017219A1 US20090017219A1 (en) 2009-01-15
US8124192B2 true US8124192B2 (en) 2012-02-28

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US (1) US8124192B2 (de)
EP (1) EP2104605B1 (de)
JP (1) JP5441897B2 (de)
AT (1) ATE501834T1 (de)
DE (2) DE102007029142A1 (de)
WO (1) WO2009000360A1 (de)

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EP2104605A1 (de) 2009-09-30
DE102007029142A1 (de) 2009-01-02
US20090017219A1 (en) 2009-01-15
ATE501834T1 (de) 2011-04-15
DE502008002871D1 (de) 2011-04-28

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